Production Resumes on Boeing 787 Dreamliners With Fifth Flight-Test Airplane

EVERETT, WA -- Production of Boeing 787 Dreamliners resumed yesterday with the join of the fifth airplane designated for flight test.

This airplane, designated ZA005, is the first to be powered with General Electric GEnx engines. The major assemblies were loaded in final body join over the past several days. The fuselage and wing joins occur simultaneously.

"This airplane signifies our return to a steady production rhythm," says Jack Jones, vice president of 787 Final Assembly and Change Incorporation. "Sections are arriving in Everett at the completion levels committed by our partners and close to what is expected for mature production. The substantial progress made by our partners streamlines the assembly process, which is essential as we ramp up production."

Five of the six airplanes designated for flight test are now in varying stages of production. Power was restored earlier this week to the first flight-test airplane, ZA001, and production testing has resumed as the airplane prepares for first flight in the second quarter. Rolls-Royce engines are hung on ZA002, in the fourth and final production position in the factory. The third and fourth flight-test airplanes, ZA003 and ZA004, are in the third and second production positions, respectively.

Fastener rework is done on ZA001, nearly complete on ZA002 and progressing well on the third and fourth airplanes, says Jones. "We have applied the resources necessary to complete all the outstanding work on these airplanes and keep the production line moving forward."

Assemblies for the final flight-test airplane, ZA006, are in production at partner sites worldwide. In all, assemblies for 30 Dreamliners are in production at this time.